Masonry wall insulation system

ABSTRACT

A disclosed masonry wall insulation system includes: a masonry wall; a bracket supported by the wall; a sheet of insulating material adjacent to the wall; and a sheet of wallboard. The wall is comprised of courses of blocks joined together with a settable medium. The bracket, which is partially embedded between two of the courses of blocks, supports the wallboard sheet adjacent to the insulating sheet. Consequently, the insulating sheet is sandwiched between the wall and wallboard. The bracket that supports the wallboard can support the sheet of insulating material in one or both of the following ways: (1) direct support beneath the bottom edge of the sheet, or (2) friction caused by the bracket sandwiching the sheet snugly between the supported wallboard and the supporting masonry wall. The system requires no separate brackets or fasteners to support the sheet of insulating material. Other systems and methods are also disclosed.

BACKGROUND OF THE INVENTION

[0001] Masonry wall construction has many benefits including durabilityand aesthetic appeal. Unfortunately, masonry walls have relatively poorthermal insulating properties.

[0002] Conventional systems are available for insulating masonry walls,but they suffer various drawbacks. For example, an article in theMarch/April 1999 issue of “Home Energy Magazine Online”(www.homeenergy.org) discloses a “semifinished concrete wall system”that adds insulation and drywall to the interior of an uninsulatedconcrete wall system. In the disclosed system, a 2×4 wood frame “falsewall” is built onto the inside of the block wall. Fiberglass battinsulation resides between the block wall and the false wall. A majordisadvantage is that two walls must be built (one masonry, one frame)for the separate functions of structural support and insulation,resulting in increased material and labor cost and construction time. Inaddition, construction of the separate walls requires the skills of twoseparate trades, namely masonry and frame construction.

[0003] Another conventional approach, disclosed in U.S. Pat. No.4,191,001, involves reinsulating a concrete block home by (1) applyinghigh-density polystyrene board on the home's exterior walls and (2)applying a polymerically bonded concrete or stucco finish to thepolystyrene board. While that technique avoids the need for constructionof a second wall, it has its own disadvantages. Masonry walls offerdurable and aesthetically appealing exterior surfaces, and the '001Patent's technique covers those surfaces with another material that maywell be less durable and less attractive.

[0004] What is still needed, in view of the shortcomings of conventionaltechniques, is a system for insulating masonry walls on the inside of astructure to preserve the beauty and durability of the masonry'sexterior surface, without adding significant time and cost to theconstruction of the wall itself.

SUMMARY OF THE INVENTION

[0005] A masonry wall insulation system according to various aspects ofthe present invention includes: a masonry wall; a bracket supported bythe wall; a sheet of insulating material adjacent to the wall; and asheet of wallboard. The masonry wall is comprised of courses of blocksjoined together with a settable medium. The bracket is partiallyembedded between two of the courses of blocks in or around settablemedium medium joining the blocks. This arrangement permits the wall toprovide firm and strong support to the bracket.

[0006] The bracket in turn supports the wallboard sheet adjacent to thesheet of insulating material. Consequently, the sheet of insulatingmaterial is sandwiched between the wall and the wallboard, where ithelps insulate the masonry wall and wallboard from each other.Advantageously, the bracket that supports the wallboard can support thesheet of insulating material in one or both of the following ways: (1)direct support beneath the bottom edge of the sheet, or (2) frictioncaused by the bracket sandwiching the sheet snugly between the supportedwallboard and the supporting masonry wall. The system requires noseparate brackets or fasteners to support the sheet of insulatingmaterial.

[0007] A masonry wall insulation system can be structured according toone or several further aspects of the invention to realize particularadvantages. For example, the insulating material can be comprised ofrigid polystyrene foam, which is a common, inexpensive material withgood insulating properties.

[0008] In addition, the bracket can include a plurality of attachmentportions that are embedded between adjacent courses of blocks at aplurality of points. A majority of the settable medium joining thecourses of blocks thus can remain free of embedded bracket portions. Insuch a configuration, the attachment portions can include adownward-extending edge part, wherein each horizontal part can rest on atop surface of one of the blocks and each downward-extending edge partcan abut an interior vertical surface at the top of the block. (Aconventional concrete block has two interior voids, bounded by interiorvertical surfaces.) Thus, the bracket can more securely rest on the topsurface before application of a settable medium and another course ofblocks.

[0009] Further, the bracket can span a plurality of blocks in at leastone of the courses of blocks. Preferably, the bracket also spanssubstantially the length of the sheet of insulating material, ensuringadequate support for the sheet.

[0010] Advantageously, the structural configuration of a bracketaccording to various aspects of the invention permits wallboard to befastened to the bracket at any suitable points along a horizontalcontinuum rather than requiring fasteners to be secured to the bracketat a specific, hidden horizontal location along a course of masonryblocks. The advantageous configuration also permits wallboard sheets tohave different widths and positioning along the masonry wall than thewidth and position of the insulating sheets, if desired.

[0011] In addition, each support part of the bracket can include anupward-extending edge part. With such a configuration, the bracket cansupport a lower portion of the sheet of insulating material. Eachsupport part can further include a vertically protruding part, e.g.,interposed between the horizontal part and the upward-extending edgepart, which permits the bracket to secure an upper portion of anothersheet of insulating material below it.

[0012] In sum, a masonry wall insulation system constructed according toall the above aspects of the invention (as is preferred but notrequired) permits convenient installation of inexpensive insulatingmaterial in a secure configuration behind protective and aestheticwallboard.

[0013] In a method for insulating a masonry wall according to variousaspects of the invention, one or more workers, suitable machinery, or acombination thereof lay a lower course of blocks. They place a bracketon top of the lower course of blocks such that a generally horizontalsupport portion of the bracket extends from the lower course of blocks.The workers, machinery, or combination thereof then lay an upper courseof blocks on top of the lower course of blocks and the bracket. Theyplace a sheet of insulating material on the support portion of thebracket, abutting the upper course of blocks. They attach to the bracketa wallboard sheet abutting the sheet of insulating material.Advantageously, the sheet of insulating material becomes sandwiched(either snugly or with a looser, gapped fit) between the blocks and thewallboard sheet where it helps insulate the masonry wall and wallboardfrom each other.

[0014] Further methods of the invention include one or more additionalacts to realize particular advantages of the various further aspects ofthe invention discussed above.

[0015] The above summary does not include an exhaustive list of allaspects of the present invention. Indeed, the inventor contemplates thatthe invention includes all systems and methods that can be practicedfrom all suitable combinations of the various aspects summarized above,as well as those disclosed in the detailed description below andparticularly pointed out in the claims filed with the application. Suchcombinations have particular advantages not specifically recited in theabove summary.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Various embodiments of the present invention are described belowwith reference to the drawings, wherein like designations denote likeelements.

[0017]FIG. 1 is a partial perspective view of a masonry wall havingembedded brackets and undergoing installation of a sheet of insulatingmaterial according to various aspects of the invention.

[0018]FIG. 2 is a partial perspective view of the masonry wall of FIG. 1with lower and upper brackets and two sheets of insulating materialinstalled according to various aspects of the invention.

[0019]FIG. 3 is a cross-sectional view of the masonry wall of FIG. 2with a sheet of wallboard secured to the lower bracket.

[0020]FIG. 4 is a partial perspective view of another type of bracketaccording to various aspects of the invention.

[0021]FIG. 5 is a partial perspective view of a base bracket accordingto various aspects of the invention installed onto a foundation surfacefor the masonry wall of FIG. 1.

[0022]FIG. 6 is an edge-on view of one of the sheets of insulatingmaterial of FIG. 2.

[0023]FIG. 7 is an edge-on view of the other one of the sheets ofinsulating material of FIG. 2.

[0024]FIG. 8 is a partial perspective view of the masonry wall of FIG. 1during embedding of the upper bracket.

[0025]FIG. 9 is a partial perspective view of the masonry wall of FIG. 1after embedding of the upper bracket.

[0026]FIG. 10 is a process flow diagram of a method of the invention forinsulating the masonry wall of FIG. 1 using the bracket of FIG. 4.

DESCRIPTION OF PREFERRED EXEMPLARY EMBODIMENTS

[0027] A masonry wall insulation system according to various aspects ofthe present invention permits convenient installation of inexpensiveinsulating material in a secure configuration behind protective andaesthetic wallboard. As may be better understood with reference to FIGS.1-3, for example, one such masonry wall insulation system 300 includes:a masonry wall 110; a bracket 130 supported by wall 110; sheets 120 and210 of polystyrene foam insulating material adjacent to wall 110; and asheet 310 of wallboard. (FIGS. 1-2 illustrate system 300 partiallycompleted.) Exemplary system 300 also includes another bracket 140 (FIG.1, not shown in FIG. 3) supported by wall 110 above bracket 130.Wallboard 310 is preferably a paper-covered gypsum slab, of ½ or ⅝ inchthickness, which is a very popular product commonly referred to as“sheet rock” or “drywall.” However, any suitable type of wallboard canbe suitably employed, including wood paneling, sheets of polymer orlaminate material, etc.

[0028] A masonry wall according to various aspects of the inventionincludes any structure formed from blocks of earthen material (claybrick, concrete block, stone, etc.) that forms a boundary. Examples ofwalls that can be of masonry construction include border and perimeterfences, sides of buildings, and soil retaining walls. As may be betterunderstood with reference to FIGS. 1-2, exemplary masonry wall 110 iscomprised of courses of blocks joined together with a settable medium. Asettable medium includes any compound that can be placed between blocksof a masonry wall to secure the blocks together, including grout ormortar comprised of a mixture of cement and water.

[0029] Bracket 130 of system 300 is partially embedded between twocourses 160, 170 of blocks in wall 110 in or around settable mediumjoining the blocks. Such an arrangement permits wall 110 to provide firmand strong support to bracket 130.

[0030] Bracket 130 supports wallboard sheet 310 adjacent to sheets 120,210 of insulating material. Consequently, sheets 120, 210 are sandwichedbetween masonry wall 110 and wallboard 310, where they help insulatewall 110 and wallboard 310 from each other. Advantageously, the sheet ofinsulating material can be supported by the bracket that supports thewallboard, by friction between the supported wallboard and supportingmasonry wall, or both. No separate brackets or fasteners are required tosupport the sheet of insulating material.

[0031] A bracket according to various aspects of the invention can bestructured from any materials (heavy plastics or lightweight metals suchas aluminum are two possibilities) and in any configuration suitable forbeing supported by a masonry wall and supporting one or more wallboardsheets. A particularly advantageous type of bracket partially embedsbetween courses of blocks in a masonry wall, in or around settablemedium joining the blocks, for firm and strong support by the wall. Asmay be better understood with reference to FIG. 3, for example, bracket130 includes: an attachment portion 360 (in addition to others not shownin FIG. 3); a generally horizontal support part 330; and anupward-extending edge part 340 at the edge of horizontal support part330. Structure of another exemplary bracket 400 (FIG. 4), which cansubstitute for bracket 130 in system 100, includes: attachment portions410, 420; a horizontal support part 430; and an upward-extending edgepart 440 at the edge of horizontal support part 430. Attachment portions410, 420 include respective horizontal attachment parts 412, 422 anddownward-extending edge parts 414, 424.

[0032] A support part of a bracket according to various aspects of theinvention can be any structural part of the bracket suitable forsupporting the bottom edge of a sheet of insulating material above it. Asupport part extends partway across the width of a bracket, from thepoint where it begins to embed in a supporting masonry wall (e.g., atthe border between the support part and the bracket's attachmentportion) to the point where a sheet of wallboard can attach to it (e.g.,an upward-extending edge part). For example, horizontal support part 430of bracket 130 spans length 496, from attachment portions 710, 722 toupward-extending edge part 740.

[0033] While all suitable brackets need not include all of the variousstructural components of brackets 130 and 430, each component providesparticular advantages. For example, parts 412, 422 and 414, 424 ofattachment portions 410, 420 advantageously hold bracket 400 in positionon top of a lower course of blocks during installation and securebracket 400 between the lower course of blocks and an upper course ofblocks above the lower course after installation. As discussed belowwith reference to FIGS. 3, 8, and 9, horizontal support part 330 ofbracket 130 provides a support surface for a sheet of insulatingmaterial, e.g., foam sheet 210 of FIGS. 2 and 3. Upper-facing edge part440 retains the lower edge of the supported sheet in bracket 130, asdepicted in FIGS. 2-3. An upward-extending edge part also provides anattachment point for fasteners (e.g., screws or nails) that securewallboard to the bracket. For example, FIG. 3 illustrates a self-tappingdrywall screw 312 with suitable threads for fastening gypsum ofwallboard 312 to upward-extending edge part 340.

[0034] A bracket according to various aspects of the invention canemploy types of attachment portions, horizontal support parts, andupward-extending edge parts different from those of exemplary bracket400 and still realize advantages of those structural components. Forexample, an attachment portion can include a shorter or longerdownward-extending edge part than part 414 of attachment portion 410. Ahorizontal support part can be completely horizontal (overall, from edgeto edge), as in part 430 of bracket 400, or it can be substantiallyhorizontal but with a slight upward tilt. (A horizontal support part mayalso tilt upward prior to installation of an insulating sheet and thenconform to a horizontal bottom edge of the sheet afterward.) Anupward-extending edge part can have any suitable height, not just theheights of exemplary edge parts 340 and 440. In addition, anupward-extending edge part can include or support additional material(e.g., a strip that can form threaded holes) to strengthen its grip on areceived fastener (e.g., a self-tapping screw).

[0035] Advantageously, bracket 400 of FIG. 4 further includes avertically protruding part 450 midway along support part 430, betweenattachment portions 410, 420 and upward-extending edge part 440. Avertically protruding part of a bracket according to various aspects ofthe invention includes any suitable structure, such as avertically-oriented surface or a ridge having a rounded or triangularcross-section, that can secure a sheet of insulating material below thebracket by preventing the upper portion of the sheet from tilting awayfrom the bracket's supporting wall. Thus a vertically protruding parthelps keep a sheet of insulating material in place until a sheet ofwallboard fastens to the bracket and encloses the sheet of insulatingmaterial.

[0036] Vertically protruding part 450 is formed from a midpoint portionof horizontal support part 430 by bends 452, 454 in material ofhorizontal support part 430. Bracket 130 of FIG. 3 includes a verticallyprotruding part 350 formed from a 90° bend in the bracket's horizontalsupport part 330, which is fully horizontal over a small portion of itslength and tilted slightly upward for the remainder. Other suitabletypes of vertically protruding parts can be employed, for example one ormore downward-pointing tabs of sheet material attached to or bent from abracket's horizontal support part.

[0037] Insulating sheets above and below a bracket having a verticallyprotruding part according to various aspects of the invention should beshaped to accommodate and engage the vertically protruding part. Asillustrated in FIG. 3, for example, sheet 120 below bracket 130 has partof its upper edge cut out to accommodate vertically (downward)protruding part 350. Sheet 210 above bracket 130 includes materialprotruding from its lower edge to engage the “backside” of protrudingpart 350.

[0038] In a variation, the bracket secures to blocks of the wall (by anysuitable type of fastener) rather than being partially embedded betweenblocks of the wall. Advantageously, a non-embedded bracket can beinstalled onto blocks of a completed masonry wall. For example, anattachment portion of a non-embedded bracket according to variousalternative aspects of the invention includes an upward-extending edgepart that abuts one or more blocks of the wall, suitable for receivingone or more concrete or masonry nails driven through the edge part andinto the block(s). Such an edge part can have any suitable dimensions,for example approximately the same height as a downward-extending edgepart of an embedded bracket's attachment portion.

[0039] A bracket according to various aspects of the present inventioncan be fabricated by any suitable technique, and from any suitablematerials. For example, exemplary brackets 130 and 400 can be fabricatedfrom a single bent piece of sheet material, preferably 24 gaugegalvanized sheet steel. Prior to bending, such a piece of sheet materialcan be cut or stamped from a larger sheet of stock material. Bracketshaving a uniform cross-section along their entire length (i.e., having asingle continuous attachment portion) can be extruded from a stock ofsuitable metal, plastic, or other suitable material. In variations wherethe simplicity of uniform material fabrication (e.g., by sheet metalbending or extrusion) is not required, a bracket's structural componentscan vary in material and thickness. For example, upward-extending edgeportions 340 and 440 can be of thicker material than other portions ofbrackets 130 and 400 to facilitate threading by a screw employed as awallboard fastener. In a variation, an upward-extending can be bent backonto itself to effectively thicken it.

[0040] An exemplary method 1000 of the invention for insulating amasonry wall may be better understood with reference to the process flowdiagram of FIG. 10 and the structural views of FIGS. 1, 5, 8, and 9.Method 1000 employs components depicted in FIGS. 8, 9, which differ fromFIG. 1 in the stages of wall construction they depict and theirsubstitution of bracket 400 (FIG. 4) for bracket 130 of FIG. 1.

[0041] Method 1000 begins with act 1010, in which a worker 150 (who canbe human or robot and can be assisted by suitable tools, machinery, orother workers not shown) places a base bracket 500 onto a building slab520 (both depicted in FIG. 5) or other suitable foundation surface formasonry wall 110. Base bracket 500 includes a horizontal support part530 and attachment flanges 540, 550 (as well as others not shown in FIG.5). Because no insulating sheet must be secured under base bracket 500,it does not include any vertically protruding part.

[0042] In act 1020 (FIG. 10), worker 150 lays a quantity of settablemedium, then a bottom course of blocks 155 (FIGS. 1, 8-9) on slab 520(FIG. 5), sandwiching attachment flanges 540 and 550 in or aroundsettable medium between slab 520 and the bottom of one side of theblocks. Dashed outline 560 represents the location of the first block ofbottom course 155. Once laid, the bottom course of blocks secures basebracket 500 to foundation 520 adjacent to the blocks. Method 1000 thencontinues with act 1030 (FIG. 10), in which worker 150 lays additionalcourses of blocks up to and including course of blocks 160 (FIG. 8).

[0043] In act 1040, after laying course of blocks 160, worker 150 placesbracket 400 on top of the blocks of course 160 such that horizontalsupport part 430 extends from course 160, as illustrated in FIG. 8.Advantageously, horizontal attachment parts 412, 422 of bracket 400 reston top surfaces of blocks in course 160 while downward-extending edgeparts 414, 424 (not shown in FIG. 8) abut vertical surfaces at the topof the blocks. (FIG. 3 depicts an example of such a surface 362 of block162, directly beneath a downward-extending edge part of attachmentportion 360 of bracket 130.)

[0044] When horizontal attachment parts 412, 422 have a lengthsubstantially equal to thickness of the walls of blocks in course 160,as is preferred, downward-extending edge parts 414, 424 exert africtional grip on the blocks. Thus, preferred attachment portions 410,420 keep bracket 400 from falling off the blocks in course 160 beforeact 1050, in which upper course 170 is laid above bracket 400, embeddingbracket 400 between courses 160, 170, in or around settable mediumjoining blocks of courses 160, 170.

[0045] In addition to laying courses in act 1050, and consequentlysecuring bracket 400 in a joint region between courses 160 and 170,worker 150 also lays successive courses of blocks on top of course 170,up to course 180. Then worker 150 places bracket 140 on top of course180 (in act 1052) and installs remaining courses of wall 110 in act1054. FIGS. 8-9 illustrate bracket 400 after completion of act 1052. Atthe beginning of act 1060, masonry wall 110 is complete, as illustratedin FIG. 1, or at least sufficiently complete for installation of sheets120, 210 of insulating material and wallboard 310.

[0046] Worker 150 performs act 1060 (FIG. 10) by placing sheet 120 ofinsulating material onto horizontal support part 530 of bracket 500 andsecuring sheet 120 under bracket 400. (FIG. 1 provides an illustrationof act 1060 with the exception that bracket 400 of FIG. 4 substitutesfor bracket 130.) Vertically protruding part 454 of bracket 400 (FIG. 4)keeps sheet 120 from tilting outward and away from wall 110 during theremainder of method 1000 through act 1080, after which wallboard 310encloses and supports sheet 120.

[0047] In act 1070, worker 150 places sheet 210 of insulating materialonto horizontal support portion 430 of bracket 400 and secures sheet 210under bracket 140. (Brackets 140 and 400 are somewhat flexible,permitting them to bend upward enough to allow a sheet of insulatingmaterial to slip in place underneath.) Then, in act 1080, worker 150attaches wallboard sheet 310 to upward-extending edge portions ofbrackets 400 and 140 with self-tapping drywall screws, e.g., screw 312of FIG. 3.

[0048] Advantageously, worker 150 performs three main tasks in thecourse of method 1000 that conventionally would be performed separately:(1) masonry construction of wall 110; (2) installation of insulation;and (3) installation of wallboard.

[0049] Exemplary method 1000 employs brackets 400 and 140 of twodifferent types, illustrating that a masonry wall insulation systemaccording to various aspects of the invention need not employ onlyidentical brackets. In an advantageous variation of method 1000,however, a structural copy of bracket 400 is installed instead ofbracket 140, providing uniformity that avoids the need for manufacturingmultiple types of brackets in addition to an optional base bracket,e.g., bracket 500. (In variations where the benefits of a base bracketare not required, it can be omitted and the lower sheet of insulatingmaterial can simply rest on the wall foundation.) Such uniformity alsoreduces the number of types of insulating sheets required to just two.(In a further variation, insulating sheets of a single type can beemployed.)

[0050] Exemplary system 300, which FIG. 3 illustrates in cross sectionand FIGS. 1-2 illustrate in part, includes brackets 130 and 140 that areof the same type. The resulting uniformity permits the use of just twotypes of insulating sheets in system 300, of which sheets 120 and 210are examples. Structural features of sheets 120 and 210, and differencesbetween them, may be better understood with reference to the edge-onviews of FIGS. 6-7.

[0051] Sheet 120 (FIG. 6) includes a bottom edge 610 and a top edge 640.Bottom edge 610 (which is flat) rests on support part 530. The shape oftop edge 640 conforms with the underside of bracket 130, as illustratedin FIGS. 1-3, and engages vertically protruding part 350.

[0052] Sheet 210 (FIG. 7) includes a bottom edge 710 that is shaped toconform with and rest on support part 330 (FIG. 3) of bracket 130. Sheet210 also includes a top edge 740 that is substantially identical to topedge 640 of sheet 120.

[0053] Structural components of a masonry wall insulation systemaccording to various aspects of the invention can each have anydimensions suitable for a particular installation and for cooperationwith other available components. TABLE I below lists preferreddimensions of exemplary components discussed above. These preferreddimensions do not in any way limit the scope of any claim that does notspecifically recite such dimensions. TABLE I FIG. Reference NumberPreferred Dimension (inches) 4 491 1 4 492 0.75 4 493 1.5 4 494 1.5 4495 0.75 4 496 3 4 497 1.5 4 498 8-9 5 591 8 6 691 23.25 6 692 1 6 693 37 791 0.75 7 792 24 7 793 1 7 794 3

Public Notice Regarding the Scope of the Invention and Claims

[0054] The inventor considers various elements of the aspects andmethods recited in the claims filed with the application asadvantageous, perhaps even critical to certain implementations of theinvention. However, the inventor regards no particular element as being“essential,” except as set forth expressly in any particular claim.

[0055] For example, one element is a bracket partially embedded betweencourses of blocks in or around a settable medium joining the blocks.Supporting a bracket from a masonry wall by embedding it between blocksof the wall provides firm and strong support to the bracket, asdiscussed above. However, the inventor contemplates that embedding thebracket can be omitted. Instead, the bracket can be secured to blocks ofthe wall with any suitable type of fastener.

[0056] Another example of a bracket contemplated by the inventor thatomits numerous advantageous but non-essential elements includes only (1)structure to be embedded between courses of blocks of a masonry wall inor around a settable medium joining the blocks, (2) an upward-extendingedge portion for attachment of wallboard to the bracket, and (3) minimalstructure for establishing a rigid connection between the embeddedstructure and the upward-extending edge portion. While such a bracketmay not itself adequately support a sheet of insulating material betweenthe wallboard and masonry wall, friction between the sheet and thesurrounding wallboard and masonry wall can perform that function.

[0057] While the invention has been described in terms of preferredembodiments and generally associated methods, the inventor contemplatesthat alterations and permutations of the preferred embodiments andmethods will become apparent to those skilled in the art upon a readingof the specification and a study of the drawings. As a case in point,the sheets of insulating material (alternatively called “insulatingsheets”) discussed above are preferred but not required to be fabricatedfrom polystyrene (extruded “XPS or “blueboard” or expanded THERMAX,“EPS,” or “beadboard”) except in claims specifying such. Alternativefoam materials include polyisocyanurate and rigid polyurethane. Indeed,sheets of any suitable insulating material can be employed, includingnon-foam materials that do not possess significant inherent rigidity.For example, composite insulating sheets can be fabricated from a coreof insulating material (e.g., fiberglass, rock wool, cellulose, etc.)surrounded by a stiffening shell (e.g., of aluminum foil, plastic,fiberglass laminate, cardboard, etc.). The stiffening shell can itselfcontain the insulating material (e.g., by surrounding it withsubstantially continuous walls). Alternatively, the insulating materialcan be contained within one or more bags or nets that are housed withinthe stiffening shell.

[0058] Additional structure can be included, or additional processesperformed, while still practicing various aspects of the invention. Forexample, insulating sheets can be modified during installation with (1)cutouts to accommodate structures conventionally mounted in a framewall, such as electrical junction or outlet boxes, and (2) surfacetrenches to accommodate wiring or tubing. In one exemplary installationprocess, e.g., performed immediately after act 1060 of FIG. 10, worker150 (FIG. 1) cuts out a 12″ by 12″ region of insulating sheet 120 andplaces an electrical junction box in the resulting void. The cutoutregion is larger then the junction box to provide working room. Uponinstallation of the box, worker 150 sprays polyurethane foam into thevoid around it to fill any gaps. To install wiring connected to thejunction box, worker 150 creates one or more trench lines in the exposedsurface of sheet 120 using a ¾″ dovetail drill bit (e.g., with a 1½″long shank). To facilitate this process, brackets 130, 140 can includeholes of suitable diameter placed periodically along their lengths,e.g., on 8″ centers.

[0059] Accordingly, neither the above description of preferred exemplaryembodiments nor the abstract defines or constrains the invention.Rather, the issued claims variously define the invention. Each variationof the invention is limited only by the recited limitations of itsrespective claim, and equivalents thereof, without limitation by otherterms not present in the claim. For example, a claim that does not callfor a bracket to include a vertically protruding part reads onvariations that include, and exclude, such advantageous but optionalstructure of a bracket.

[0060] In addition, aspects of the invention are particularly pointedout in the claims using terminology that the inventor regards as havingits broadest reasonable interpretation; the more specificinterpretations of 35 U.S.C. § 112(6) are only intended in thoseinstances where the terms “means” or “steps” are actually recited. Thewords “comprising,” “including,” and “having” are intended as open-endedterminology, with the same meaning as if the phrase “at least” wereappended after each instance thereof. A clause using the term “whereby”merely states the result of the limitations in any claim in which it mayappear and does not set forth an additional limitation therein. Both inthe claims and in the description above, the conjunction “or” betweenalternative elements means “and/or,” and thus does not imply that theelements are mutually exclusive unless context or a specific statementindicates otherwise.

What is claimed is:
 1. A masonry wall insulation system comprising: (a)a masonry wall comprised of a plurality of blocks joined together with asettable medium; (b) a bracket supported by the wall, a part of thebracket held by the settable medium joining two of the courses ofblocks; (c) a sheet of insulating material adjacent to the wall; and (d)a sheet of wallboard supported adjacent to the sheet of insulatingmaterial by the bracket; wherein (e) the sheet of insulating material issandwiched between the wall and the wallboard.
 2. The system of claim 1wherein the insulating material is comprised of rigid polystyrene foam.3. The system of claim 1 wherein the bracket comprises a plurality ofattachment portions embedded in the settable medium at a plurality ofpoints.
 4. The system of claim 3 wherein each attachment portionincludes a horizontal part and a downward-extending part, wherein eachhorizontal part is structured to rest on a top surface of one of theblocks and each downward-extending part is structured to abut a verticalsurface inside a recess of the block at the top of the block.
 5. Thesystem of claim 1 wherein the bracket spans a plurality of blocks in oneof the courses.
 6. The system of claim 5 wherein the bracket spanssubstantially the length of the sheet of insulating material.
 7. Thesystem of claim 5 wherein the bracket spans at least the length of thesheet of wallboard.
 8. The system of claim 5 wherein the settable mediumis free of embedded bracket portions along a majority of the length ofthe courses of blocks.
 9. The system of claim 1 wherein the bracketcomprises a generally horizontal part extending from the settable mediumand an upward-extending part at the end of the generally horizontalpart, wherein the bracket is shaped to support a lower portion of thesheet of insulating material thereon.
 10. The system of claim 9 whereinthe generally horizontal part of the bracket and the sheet of insulatingmaterial have widths that are substantially uniform and equal.
 11. Thesystem of claim 9 wherein the generally horizontal part includes avertically protruding part interposed between the horizontal andvertical parts of the bracket, wherein the vertically protruding part isshaped to engage an upper portion of another sheet of insulatingmaterial below the bracket.
 12. A method for insulating a masonry wall,the method comprising: (a) laying a lower course of blocks; (b) thenplacing a first part of a bracket partially above the lower course ofblocks such that the lower course of blocks supports a first part of thebracket and a generally horizontal second part of the bracket extendsbeyond an edge of the lower course of blocks; (c) then securing an uppercourse of blocks to the lower course of blocks and the first part of thebracket; (d) then placing a sheet of insulating material next to theupper course of blocks on the second part of the bracket, wherein athird part of the bracket extends beyond the insulating sheet; and (e)attaching a wallboard sheet to the third part of the bracket; wherebythe bracket is partially embedded between the lower and upper courses ofblocks, the bracket supports the wallboard sheet, and the insulatingsheet is sandwiched between the blocks and the wallboard sheet.
 13. Themethod of claim 12 wherein placing the sheet comprises placing a sheetof insulating material that is comprised of rigid polystyrene foam. 14.The method of claim 12 wherein: (a) the method further comprises placinganother bracket above a course of blocks laid above the upper course ofblocks; and (b) placing the sheet comprises fitting the sheet ofinsulating material in position between the brackets.
 15. The method ofclaim 12 wherein securing the upper course of blocks to the lower courseof blocks and the bracket comprises partially embedding the bracket inor around settable medium between the lower and upper courses of blocks.16. The method of claim 15 wherein securing the upper course of blocksto the lower course of blocks comprises embedding portions of thebracket in settable medium at positions extending along a minority ofthe length of the courses of blocks.
 17. The method of claim 12 whereinplacing the first part of the bracket further comprises securing ahorizontal part and a downward-extending edge part of the bracket to atop surface and a vertical surface, respectively, at the top of one ofthe blocks in the lower course.
 18. The method of claim 12 wherein: (a)placing the bracket further comprises using a bracket that includes avertically protruding part interposed partway across the width of thegenerally horizontal part; and (b) the method further comprises securingan upper portion of another sheet of insulating material below thebracket and below the upper course of blocks, wherein the verticallyprotruding part keeps the insulating sheet below the bracket fromtilting outward.
 19. A masonry wall insulation system comprising: (a) amasonry wall; (b) a sheet of rigid polystyrene foam; (c) a sheet ofwallboard; and (d) means for supporting the wallboard from the wall suchthat the foam sheet is sandwiched between the wall and the wallboard;whereby the foam sheet provides thermal insulation between the wallboardand the wall.
 20. A bracket structured to be supported by a plurality ofstandard-sized cement blocks having interior voids and exterior walls,the bracket comprising: (a) a generally horizontal part extendingsubstantially the length of the bracket; (b) a plurality of attachmentportions disposed substantially equidistant from each other along thelength of the generally horizontal part at a first edge thereof, each ofthe attachment portions including: (1) a horizontal section matching thewidth of an exterior wall of a block; and (2) a downward-extendingflange at the end of the horizontal part away from a first edge of agenerally horizontal part; and (c) an upward-extending ledge extendingsubstantially the length of the bracket at a second edge of thehorizontal part opposite the first edge.
 21. The bracket of claim 20further comprising a vertically protruding part extending substantiallythe length of the horizontal part and interposed partway across thewidth of the generally horizontal part.